Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 1

Operating Manual

1364 Hamilton Parkway Itasca, Illinois 60143 888-200-1800

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 2

Copyright ©2011 EquipSolutions All rights reserved No part of this publication may be duplicated and/or published through printing, photo-copying, microfilm, electronically or via audio tapes or be stored in any other manner without prior written consent from the publisher

Thank you for your investment in the Tempest Polymer Feed and Control Station. The Tempest Series of liquid polymer feed and control stations are designed to provide maximized polymer performance without the hassles and headaches these applications cause for water treat-ment professionals. The system design provides the right type of mixing energy at the critical moment of initial wetting and tapers that energy through a multi-stage regime of hydrating zones. The net result is a fully hydrated polymer solution with maximum charge site exposure which assures optimized polymer usage and performance. The design eliminates unwanted agglomerations, plugging and the costly mess of dealing with these issues. The unit operation is simple. The user enters the desired polymer concentration and selects manual or automatic operation. Primary dilution water flow is controlled by a solenoid valve which allows water to enter the unit. Primary dilution water flow rate data is measured continuously to assure that adequate flow is present and fed back to the Tempest controller. Using calculations derived from the calibration stage, the unit automatically adjusts the polymer pump output to achieve the desired concentration. Under conditions of high or low concentration, a loss of water flow or polymer feed (optional) the system automatically shuts down and notifies with an alarm. Each feed cycle is followed by an ad-justable, multi-stage flush cycle to eliminate any plugging . The sys-tem can be operated remote via a 4-40mA or simple on/off signal. The Tempest is backed by a One Year Warranty. Please call us if we can be of assistance in any way.

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 3

TABLE OF CONTENTS

Introduction………………………………………………. 4 Selection and Pump Guide…………………………… 5 General Arrangement Drawings…………………..…. 6

Front Layout of Tempest ..……………………………... 8 Back Layout of Tempest……………...………………... 9 Inlet and Outlet Connections for fluids………….…… 10 Electrical Connections…………………………………. 11 TEMPEST Controller Overview……………………..….. 12 Main Menu Navigation………………………………… 13-17 TEMPEST Controller Wiring Diagram…………………. 18 TEMPEST Controller Menu Tree………………………... 19 Installation & Start Up……………………………..……. 20-23 Post-Dilution …………………………………….….…….. 24 Maintenance Planner…………………………….…….. 25 TEMPEST Controller Set-Point Data Sheet……………… 26 TEMPEST Controller Specifications…………………… 27 Notes Page……………………………………………..…. 28

P&ID Drawing…………………………………………….. 7

Operating Manual

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 4

The Tempest™ Polymer Feed System is a self-contained system designed to control feed water and polymer and combine them to produce a high quality solution. The system is designed to receive an Emulsion, Solution or Mannich polymer and mix with feed water to pro-duce and discharge a quality solution from the system. The Tempest™ Polymer Feed System can be enabled in local mode (simple On / Off operation) or remotely via a customer supplied dry contact which will Stop/ Start the Tempest™ Polymer Feed System. In local mode, the Tempest™ Polymer Feed System can be operated based on “override” manual set points or internal flow pacing set points . The manual “override” mode allows the user to manually adjust the rotameter and pump capacities locally. The internal flow pacing mode, allows the Controller to pace the neat polymer metering pump volume output to the flow of water to hold the solution at a set concentra-tion point which is selected in the TEMPEST CONTROL-LER. In remote mode, the Tempest™ Polymer Feed System offers two control options as well. In the Remote Con-centration mode, the Controller receives a remote an-alog signal to adjust the desired concentration set point while the dilution water flow remains constant. Remote Rate mode receives a remote analog signal to adjust to the pump speed. Either remote mode option can be achieved with the remote disable selection on the ON or OFF position. A complete skid mounted system; the Tempest™ Poly-mer Feed System is equipped with all the necessary components for easy installation, reliable performance and safe operation. The design incorporates an elec-tric solenoid valve (water), flow meter/switch, manual-ly adjustable rotometer, electric solenoid diaphragm pump (Polymer), TEMPEST controller, manual ball valves, calibration column, PVC piping and compo-nents, all on a SS frame to provide the durability to with-stand harsh conditions and minimize maintenance. This manual is designed to provide simple explanations on how to use the System. The layouts in this manual were done in an effort to “literally” walk you through the system’s operations.

INTRODUCTION

Key Features Easy Access Design Motorless, Mult i-Stage Mixing Hydro-Kinetic Disperser EZ View Mixing Chamber Choice of Pump Type Choice of Pump Manufacturer Touch Pad Microprocessor Polymer Paced to Water F low Local and Remote Operat ion Water F low Readout Concentrat ion Set-Point 4-20mA Output S ignal Isolated Pulse Dr iver Three Control Relays Remote 4-20 mA Control Feed Rate Cal ibrat ion Adjustable F lushing Cycle High/Low Solut ion L imitat ion Manual or Remote Start Remote Set Point Control On-Board Post Di lut ion Rugged Construction Key Benefits Optimized Polymer Performance Minimized Polymer Waste Low Maintenance Broad Appl icat ion Range Economical Simple to Instal l and Operate Flexible Controls Spare Parts Easy to Get Rapid Delivery Proven Rel iabi l i ty Hassle Free Maintenance

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 5

SELECTION & PUMP GUIDE

DESIGNATOR MAKE AND MODEL NUMBER

FLOW GPH PRESSURE

D.4 AD841-626VP 0.02 - 0.4 140PSIG

D1 AD851-636VP 0.05 - 1 110PSIG

D2.5 B721-86HV 0.1 - 2.5 100PSIG

D4 C721-76HV 0.2 - 4 100PSIG

D8 C731-20HV 0.3 - 8 100PSIG

PUMP GUIDE

ELECTRICAL SUPPLY 

ALL UNITS OPERATE AT 110 VAC 60 Hz 10 AMP SERVICE

TPS-150-D1

Primary Dilution Water Flow

Designates Tempest Series Designates Metering Pump

Tempest Selection Table

Primary Dilution Water Range* Neat Polymer Range Model Number Rated GPH Min GPH Max Inlet Pressure Min GPH Max GPH

VB-60-D.4 60 6 100 PSI 0.04 0.40 VB-60-D1 60 6 100 PSI 0.10 1.00 VB-150-D.4 150 15 100 PSI 0.04 0.40 VB-150-D1 150 15 100 PSI 0.10 1.00 VB-150-D2.5 150 15 100 PSI 0.25 2.50 VB-150-D4 150 15 100 PSI 0.40 4.00 VB-300-D1 300 30 100 PSI 0.10 1.00 VB-300-D2.5 300 30 100 PSI 0.25 2.50 VB-300-D4 300 30 100 PSI 0.40 4.0 VB-600-D2.5 600 60 100 PSI 0.25 2.50 VB-600-D4 600 60 100 PSI 0.40 4.00 VB-600-D8 600 60 75 PSI 0.80 8.00 VB-1200-D4 1200 120 100 PSI 0.40 4.00 VB-1200-D8 1200 120 75 PSI 0.80 8.00

* Secondary Dilution is standard on all units. Secondary Dilution rates are identical to Primary rates

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 6

GENERAL ARRANGEMENT

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 7

P&ID

Connections Model Range Water Inlet Polymer Inlet Solution Outlet VAC

TPSG-300 1" FNPT 3/4” FNPT 1" FNPT 110 TPSG 600 & 1200 1-1/2" FNPT 3/4" FNPT 1-1/2" FNPT 110

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 8

THE LAYOUT FRONT VIEW

EZ View Mul ‐Stage                             Mixing Chamber 

 Controller 

EZ View High Energy Mixing Tee  

Primary Neat Polymer Pump 

Neat Polymer Feed Rate Calibra on Assembly 

Secondary Dilu on Water  Flow Control Valve 

Polymer Solu on Discharge 

Water Pressure Gauge 

Primary Dilu on Water Flow Control Valve 

Secondary Dilu on Water  Rotometer 

Primary Dilu on Water  Rotometer 

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 9

BACK VIEW THE LAYOUT

Rugged Tubular SS Frame  

Dilu on Water  Inlet 

Neat Polymer Inlet 

PVC Back Plane 

Main Dilu on Water Solenoid Valve 

Dilu on Water Meter 

Op onal PC Pump Loca on 

Secondary Dilu on Water Circuit 

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 10

SOLUTION OUTLET 1” FNPT CONNECTION

CONNECTIONS

POLYMER INLET 3/4” FNPT CONNECTION

WATER INLET 1” FNPT CONNECTION

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 11

ELECTRICAL CONNECTIONS

The system is supplied with a standard US three prong plug for single phase 110 VAC. This plug supplies electricity for the TEMPEST polymer dosage Controller and the metering pump through a splash-proof GFI receptacle.

110 VAC SUPPLY VOLTAGE

Two Configurable Analog Control Modes: 4-20 mA DC input for control of concentration from 0.1-1.5% or 4-20mA DC input for proportional flow. Remote stop start: voltage free contact closure to remote stop and start the sys-tem. A 110 VAC alarm is provided to alert to loss of water flow, high water flow, and polymer concentration alarm.

A ten foot multi-pin cable, part number TEMPEST CONTROLLER 0-AR, is in-cluded with the system to make customer remote control connections for analog input and remote stop start. Note: Please contact factory for addi-tional length for your multi-pin cable assembly. The alarm requires connection to the terminal strip inside the TEMPEST Controller. (See drawing on page 18)

TEMPEST POLYMER DOSAGE CONTROLLER

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 12

When placed in operation with the external devices properly installed and connected, power the system to display STANDBY. Enter the main menu to set the various parameters and calibrate the pump. Exit the main menu to show STANDBY and press an arrow key to set the desired concentration level. Press Enter to show STANDBY. Press Enter again to place the unit in opera-tion. The display will scroll between the water flow rate and preset percent concentration level. Pressing Enter will stop the pump operation and complete the flush se-quence. The SOFT MENU allows placing the Controller in STANDBY or OPERATE by toggling the ENTER keypad. The unit al-ways enters the STANDBY mode during power up or exit-ing the main setup menu. When the unit is in STANDBY or OPERATE, pressing an ar-row key will display the current concentration level. Pressing either arrow key allows changing the concen-

Remote operation of the Tempest can be configured in two different control modes. When configured for REMOTE CONCENTRATION operation, a 4-20 mA DC signal input will allow changing the pumping rate over the complete 0.01 to 1.5% concentration range within the lim-its of water flow and pump capacity. The pump rate will follow the instantaneous water flow to maintain the desired concentration as set by the remote 4-20 mA DC control signal. When configured for REMOTE RATE operation, a 4-20mA DC signal input will allow changing the pump output (capacity) rate over the complete range of the metering pump. A minimum 4-20 mA DC signal in either mode will cause zero pumping rate although the water solenoid valve will be powered on open. If the remote disable line is installed, the system can be disabled by opening the disable pair to turn off the pump and initiate the flush sequence.

TEMPEST CONTROLLER OVERVIEW

REMOTE OPERATION

During either local or remote operation, the alarm will activate if either the water flow is below the present low level set point or if the concentration level cannot be satisfied caused by inad-equate water volume or inadequate pumping capacity. The CONC ALM action will turn the pump OFF, enter the flush cycle and activate the alarm output. The FLOW ALM is a configura-ble set point ranging from 0-30 seconds. If flow can be re-established within the selected time range the unit will re-engage. If the alarm mode times out an alarm indication will be activat-ed. The TEMPEST Controller display will show either CONC ALM alarm or FLOW ALM alarm. Either condition must be corrected to place the unit back in operation.

ALARMS

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 13

User programmable options for setup are accessed by pressing the UP ARROW and DOWN ARROW KEYS simultaneously for five (5) seconds. After entering the correct pass word, use UP/DOWN KEYS separately to scroll through the Menu options and press ENTER to activate the selected option. If the keypad sees no activity for sixty seconds, the unit will time out and automatically revert to standby mode. The Setup Menu Flow Chart included on page 18 will assist in the programming procedure. Upon entering the setup mode with the correct password, (factory default password is 7777) the following selections are available by scrolling using the ARROW KEYS. CONTROL (Selects local or remote operation) ( Rate or Conc) REMOTE DISABLE (Selects remote disable ON/OFF) MAX STKS (Selects pump maximum stroke per minute) CAL PUMP (Calibrates pump) FEED DLY (Delay time-water flow—pump ON) FLOW (Selects flow units) FLUSH (Selects water flush operation) ALARM (Selects alarm parameters) DISPLAY (Selects English or Metric units) 4-20 (Calibrates 4-20 mA DC Input/Output) PRIME (Allows turning pump on) PASSWORD (Password changing) FACT RST (Factory Reset Program) EXIT (Unit enters standby mode)

The following descriptions are detailed guidelines for setting up your TEMPEST Controller. Allows selecting either Local or Remote operating control mode. Selecting Local means the poly-mer pump will be controlled locally at the Controller to maintain the preset percentage concen-tration. When configured for REMOTE CONCENTRATION operation, a 4-20 mA DC signal input will allow changing the pumping rate over the complete 0.01 to 1.5% concentration range within the limits of water flow and pump capacity. The pump rate will follow the instantaneous water flow to maintain the desired concentration as set by the remote 4-20 mA DC control signal. A minimum 4-20 mA DC signal will cause zero pumping rate although the water solenoid valve will remain ener-gized in open position. When configured for REMOTE RATE operation, a 4-20mA DC signal input will allow changing pump output over the full range of the metering pump. If the remote disable line is installed, the system can be disabled by closing the disable pair to turn off the pump and initiate the flush sequence. The selected control mode is saved by pressing the

Enter key.

MAIN MENU NAVIGATION

RMT DISABLE

CONTROL

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 14

CONTROL MODES

TEMPEST Control mode: The Tempest TEMPEST Controller provides four (4) different operational modes. The user must decide which control mode is appropriate for their application.

Local / Rate: Neat polymer is controlled locally at the TEMPEST Controller by manually adjusting the target feedrate (gph).

Remote / Rate: Neat polymer is proportionally controlled by a remote signal (4-20mA) wired

to the TEMPEST Controller based on neat polymer feedrate (gph) Local / Conc: Neat polymer is proportionally paced with the measured water flow to

achieve the target concentration (%), prescribed locally at the TEMPEST Controller. Remote / Conc: Neat polymer is proportionally paced with the measured water flow to

achieve the target concentration (%), prescribed by a remote pacing signal (4-20mA) wired to the TEMPEST Controller.

STEP 1: Using the Arrow key (s) scroll through the menu until CONTROL is displayed. STEP 2: Press Enter button to enter control mode selection.

STEP 3: Use the arrow keys to scroll to the desired control arrangement. Local/ Conc Local/ Rate Remote/Conc Remote/Rate STEP 4: Once the desired control mode is displayed press the ENTER key to confirm acceptance

1  2 

3  4 

CONTROL 

LOC RATE 

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 15

MAIN MENU NAVIGATION

MAX STROKES

CAL PUMP

FEED DLY

Allows setting the maximum stroke rate in pulses per minute when using an electronic type pump. LMI pumps specify a maximum stroke rate of 100 pulses per minute. Select new maxi-mum stroke rate using arrow keys. The selected maximum stroke rate is saved by pressing the Enter key.

Allows calibration of the polymer pump. The operator must decide on the calibration volume, pump stroking rate in percent of full pumping rate, pump stroke length percentage and record on the setup parameter sheet. Press Enter to show the default 500 milliliter pump down calibrate volume. Select a new vol-ume using the arrow keys. Press Enter to show default 50 percent for the full percent pumping rate. Select new pumping rate using arrow keys for calibration. If an LMI style electronic pump is incorporated with maximum 100 strokes per minute, then a setting of 0 to 100 percent equals 0 to 100 strokes per minute. Press Enter to record the % stroke length as reference only. The stroke length is not controlled. The value entry has no effect on the pump operation and is on-ly for future reference when calibrating the associated pump. Changing the pump stroke length after calibration will result in incorrect concentration calculations. Next press Enter again to display Start to power the water solenoid valve. When the polymer pump is ready to start operating with the calibration tube filled to the selected volume, press Enter again. The polymer pump will be energized and the display will show Stop. When the calibration volume has been precisely pumped down, press Enter again. The unit displays CAL?NO. To accept the calibration press either Up/Down key to change the display to read CAL?YES, then press Enter. The display will momentarily read Saving. To de-cline the calibration, press Enter when the display reads CAL?NO. The display will momentarily read ABORTED! The previous or default calibration numbers will be used. Press the Down key for the next setup selection, or repeat the CAL PUMP option. The selected polymer pump flow calibration mode is saved by pressing the Enter key.

Feed delay sets a delay time between water flow detection and the polymer feed pump turn-ing ON. Prevents polymer being fed before the mixing chamber is full of water.

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 16

MAIN MENU NAVIGATION

FLUSH

ALARM

DISPLAY

4-20mA

Sets the time period in seconds to maintain dilution water flow after the polymer pump is turned off and the system is placed in standby. The RPT (repeat) sets the number of times the initial flush will be repeated, with ten (10) cycles available each with a set four (4) second off delay between flush operations. The selected flush parameters are saved by pressing the En-ter key. Low flow allows selecting the low dilution water flow rate causing the Lo Flo alarm function to operate. To change the value press the Enter Key and enter a new value using the arrow keys. Save the value by pressing Enter. The next step allows a configurable alarm range set point from 0-30 seconds

Low flow allows selecting the low dilution water flow rate causing the Lo Flo alarm function to operate. To change the value press the Enter Key and enter a new value using the arrow keys. Save the value by pressing Enter. The next step allows a configurable alarm range set point from 0-30 seconds

Allows user to select English or Metric units for display

Allows calibrating both the 4-20 mA DC input and output. Use arrow keys to select Input or Output. Calibrate Input: Two point calibration of remote control input. Remove input connection to Controller. Input 4 mA DC from a precision current source. The display will show 4 mA DC In, then press Enter on keypad. With the display reading 20 mA DC apply 20 mA DC from the pre-cision current source. Wait at least five seconds to allow the signal to settle, then press Enter on the keypad. The display will show CAL?NO. Press Enter if a new calibration is not desired. Or, press an arrow key to display CAL?YES if a new calibration is desired. Then press Enter to accept the new calibration.

FLOW Allows selecting flowmeter calibration and readout parameters. Pressing Enter allows selecting either English or Metric flow units for dilution water. The pump units are only in metric. The se-lected unit parameters are saved by pressing the Enter key. The maximum flow for dilution water input is selected based upon the size of flowmeter select-ed. The Menu allows inputting the “K” value for the particular flowmeter. “K” value refers to the number of pulses per gallon of water for the specific flowmeter utilized. The “K” value is fac-tory set before shipment. When the Enter Key is pressed, a factory set default number will be displayed. To change, press an arrow key to increase or decrease, then press Enter. Press Enter to return to the Menu after the number is complete. Press the arrow key for the next selection.

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 17

MAIN MENU NAVIGATION

PASSWORD

FACT RST

EXIT

A previously programmed password must be entered to access the Menu options. Starting with the left position, use the arrow keys to select the correct number, then press Enter. Pro-ceed through all four digit positions and press Enter. The correct password will allow access to the Menu options. The incorrect password will place the unit into the standby mode. A default password is necessary to enter the main menu used for changing various operating parameters. Following the prompts can change the password. Once changed, the new pass-word must be utilized to enter the main menu. If the new password is forgotten, the unit must be returned to the factory to reinitialize the default password.

In the event the factory default values must be reloaded into the Controller, press the Enter key. The unit will momentarily display YES/NO. Selecting NO will retain the previous program values. Selecting YES the unit is now ready for new programming, or ready as programmed to the de-fault values. However, the unit must be calibrated as previously explained for optimum opera-tion.

Press the arrow key to show EXIT. Pressing Enter will place the unit in standby, or an arrow key to select another menu operation. If any key is not activated for 60 seconds, the unit will automatically start operating, except in the CAL PUMP mode.

PRIME

Allows the operator to energize the chemical metering pump and at maxi strokes to help prime the pump. Scroll to PRIME and hit Enter to energize the pump. Hit Enter again to stop the pump.

4-20mA

Allows calibrating both the 4-20 mA DC input and output. Use arrow keys to select Input or Output. Calibrate Input: Two point calibration of remote control input. Remove input connection to Controller. Input 4 mA DC from a precision current source. The display will show 4 mA DC In, then press Enter on keypad. With the display reading 20 mA DC apply 20 mA DC from the pre-cision current source. Wait at least five seconds to allow the signal to settle, then press Enter on the keypad. The display will show CAL?NO. Press Enter if a new calibration is not desired. Or, press an arrow key to display CAL?YES if a new calibration is desired. Then press Enter to accept the new calibration.

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 18

TEMPEST CONTROLLER WIRING DIAGRAM

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 19

TEMPEST CONTROLLER MENU

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 20

POLYMER SUPPLY INSTALLATION

FLOODED SUCTION OR PUMP ABOVE POLYMER SUCTION LIFT

Flooded Suction Installation After the polymer supply is connected to the neat polymer inlet connection, open the neat polymer inlet ball valve. Next, open the priming valve on the inlet to the pump and by using the sy-ringe supplied in the CMS priming kit, apply syringe tip to the barb fitting. Commence pulling air out of the suction line using the syringe. This will require a repetitive procedure of opening and closing the priming valve until polymer has been drawn to the pump head.

Polymer Suction Lift Installation - In some cases it may be helpful to fill the calibration column with polymer and pump from the column to get the pump primed and exert maximum suction lift.

Suction lift is limited to four feet and requires a suction lance. Part # CP-POLY-LIFT

PRIMING KIT : Part # CP-POLY-PK

PRIMING THE POLYMER PUMP

INSTALLATION & START-UP

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 21

INSTALLATION & START-UP

PASSWORD PROCEDURE

PWD **** 

STEP 1: At the TEMPEST Controller simultaneously press and hold both arrow keys for 3 seconds to enter the set-up mode.

At the prompt, enter the 4 digit password (7777) by using the arrow keys and confirming each digit by pressing the enter button.

After the TEMPEST Controller initializes, it will display “ STANDBY”. You’ll need to enter a password to set up the Controller.

TO START SET UP 

1  1 

Page 4 

PWD 7***  PWD 7*** 

PWD 77**  PWD 777* PWD 77** 

SCROLL TO  SELECT SECOND PASSWORD DIGIT 

CONFIRM SECOND  PASSWORD  

DIGIT SELECTION 

SCROLL TO  SELECT THIRD PASSWORD DIGIT..ETC 

PWD 7777  PWD 7777 

COMPLETE THE            4 DIGIT PASSWORD 

CONFIRM PASSWORD 

CONTROL 

READY FOR SET UP 

SCROLL TO  SELECT FIRST PASSWORD DIGIT 

CONFIRM FIRST PASSWORD  DIGIT SELECTION 

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 22

The Tempest system directs and manipulates hydraulic force to invert and homogenize the polymer solution. It requires a pressure range 26 psi above the injection point and no higher than 90 psi. The dilution water isolation ball valve needs to be opened (1). The solution outlet isolation valve also needs to be opened(2). If required before start up, the solenoid can be opened by entering the menu password and cycling to the solenoid test (FLUSH) menu. Selecting yes and hitting enter will cause the sole-noid to fire and stay open until enter is hit again.

The polymer pump needs to be calibrated to the specific polymer that you will be using to treat the process. The operator must decide on the pump stroke length percentage for the calibration and operation. The system ships with 100% stroke length as factory default. Changing the stroke length after calibration will put the system out of calibration. The Controller has a place to record the stroke length in nonvola-tile memory. Fill the calibration column with 500 ml of polymer. Isolate the calibration column from the polymer supply. Hold down the up and down arrows for five second to access the TEMPEST controller menu. Enter the password 7777 or the password that you have set in the Controller.

CALIBRATION OF POLYMER PUMP

2

DILUTION WATER

INSTALLATION & START-UP

1

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 23

The Tempest uses a paddlewheel flow meter (Fig. 1) to ratio the polymer addition to the primary water dilution. Primary and Secondary dilution water rate is manually adjusted. A rotometer is supplied to assist the operator in making adjustments and is for visual indication only. The flow meter is factory preset and calibrated against a test flow meter at the factory. The flow meter reads out on the TEMPEST polymer dosage controller display. The Primary dilution flow adjustment is done through the gate valve at the top of the feeder. (2) and secondary (3) dilution is done through the valve on the right side, next to the primary and secondary rotometers. You will notice that as the flow increases or decreases the polymer pump will speed up or slow down.( In Concentration mode)

FIGURE 1 FIGURE 3

Use the down arrow to go to the calibrate menu.

Press Enter to show the default 500 milliliter pump down calibrate volume. Press Enter to show default 50 percent for the full per-cent pumping rate. Press Enter to record the % stroke length as reference only. The stroke length is not controlled. The value en-try has no effect on the pump operation and is only for future ref-erence when calibrating the associated pump. Changing the pump stroke length after calibration will result in incorrect concentration calculations. Next press Enter again to display Start to power the water sole-noid valve. When the polymer pump is ready to start operating with the calibration tube filled to the selected volume, press Enter

again. The polymer pump will be energized and the display will show Stop. When the calibra-tion volume has been precisely pumped down, press Enter again. The unit displays CAL?NO. To accept the calibration press either Up/Down key to change the display to read CAL?YES, then press Enter. The display will momentarily read Saving. To de-cline the calibration, press Enter when the display reads CAL?NO. The display will momentarily read ABORTED! The previous or default calibration numbers will be used. Press the Down key for the next setup selection, or repeat the CAL PUMP option. The selected polymer pump flow calibration mode is saved by pressing the Enter key.

SETTING THE DILUTION WATER FLOW

INSTALLATION & START-UP

FIGURE 2

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 24

Example - 1gph neat polymer / 100gph primary dilution = 1% make-up concentration 100 gallons of 1% make-up solution / 100gph post dilution = 0.005% final feed concentration

POST DILUTION

The Tempest system includes a Post Dilution Circuit as a standard feature. The secondary rate control valve allows a flow rate equal to the primary flow rate to be added to the solution after it exits the mixing chamber. By opening the post dilution gate valve, the polymer solution make-up concentration can varied to achieve a final feed concentrationThe rate is displayed on a rotometer directly adjacent to the control valve.

Secondary Dilution Water Control

Valve

Secondary Dilution Water Rotometer

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 25

Problem Possible Cause Remedy No water flow

Water supply failed No electrical power Dirt in solenoid valve

Check water pressure Check power supply Clean valve

No solution, only water

Polymer isolating valve closed Air in polymer pump Polymer pump defective Polymer check valve clogged

Open valve Re-prime pump Overhaul pump Clean

Solution strength varying

Pump head/valve fault Partial blockage in: Polymer check valve, Mixing tee, Water flow meter Varying water supply pressure

Clean pump head and valves. Replace pump Clean Check water pressure at period of peak demand. Check if other water users restrict supply to feeder. Consider in-stalling a booster pump.

MAINTENANCE PLANNER

MAINTENANCE PLANNER

MAINTENANCE ITEM

Wee

kly

Ever

y 6

mon

ths

Annu

ally

Next Planned Maintenance DateCheck pump calibration xCheck water flow xInspect & clean all check valves xInspect & clean Mixing Tee xInspect system for leaks or damage xInspect all supply and discharge lines x

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 26

POLYMER DOSAGE CONTROL (TEMPEST CONTROLLER) DESCRIPTION 1.EIGHT DIGIT ALPHA-NUMERIC DISPLAY a. When operating, the display provides real-time Parameters as values and/or unit status. b. During programming mode, the display shows the programmed information for each input and preset value. 2.KEYPAD a. Enter - Used to enter, start and stop operation b. Arrows (up and down) - Used to scroll through the various parameter settings and change the number

TEMPEST CONTROLLER SET

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 27

Inputs: Provided by: a. 4-20 mA DC Input signal Customer supplied remote signal b. Unpowered contact closure Customer supplied dry contact Outputs: Function: a. Water solenoid valve SSR #1 relay I Inlet water valve actuation b. Alarm control SSR #2 relay Low water flow & concentration alarm relay c. Pump power, SSR #3 relay Pump Power d. Pulse output, Isolated dry contact Controls pulse driven polymer pump e. 4-20 mA Output Operates 4-20 mA controlled polymer pump Display: Eight (8) digit, 0.3 inch high alphanumeric red LED. Resolution +/- one digit. Temporary or long-term power loss does not affect program setups. Water Power Solenoid Control Output: Solid state powered relay, contact clo-sure, SPST, 5 ampere N.O. may be connected for controlling AC loads. Alarm Power Output: Solid state powered relay, contact closure. SPST, 5 am-pere N.O. may be connected to signal for alarm purposes. Also operates dur-ing low dilution water flow error, Lo/High concentration error. Pump Power Output: Solid state powered relay, contact closure, SPST, 5 ampere N.O. may be connected for controlling AC loads. Electronic Pump Control: Solid state switch contact closure, SPST, 100 mA DC 12 VDC, isolated Input Operating Voltage: 100 to 240 VAC, 60/50 Hertz. Fuse, 3AG, 5 ampere (slo-blo) for solid state relay loads. Programming: Three (3) button keypad embedded in panel label allows pro-gramming and Controller operation. Enclosure: PVC, NEMA-4X Size: 7” L-R 7" T-B 3" Depth

TEMPEST CONTROLLER SPECIFICATIONS

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 28

___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________

NOTES

Tempest Polymer Feed and Control Station – May 2012- Rev. 2.0 PAGE 29

1364 Hamilton Parkway, Illinois, 60143

Phone : 888-200-1800 Fax: 630-351-9080

www.equip-solutions.com